Railway wagon composite material side wall and manufacturing method

Abstract

The invention relates to a railway wagon composite material side wall and a manufacturing method, and relates to the technical field of railway freight train technical inspection. The skin comprises a skin body, an inner skin body and an outer skin body. The first supporting assembly is arranged in the skin and comprises a cross beam assembly and a side edge vertical beam; the second supporting assembly is arranged in the skin and comprises a vertical beam assembly and an inclined connecting beam; the interior of the skin is filled with the filling assembly; the cross beam assembly, the vertical beam assembly and the side edge vertical beam are all of a composite material structure scheme, and compared with an existing most advanced aluminum alloy side wall, the weight can be reduced by 30% or above; the cross beam assemblies, the vertical beam assemblies, the side edge vertical beams, the inclined connecting beams and the third sandwich materials are all solidified in the skin, the outer surface of the side wall is simple in structure and is of a structure without outer side columns, and therefore the truck limit can be fully utilized, and cargoes left in a truck can be conveniently cleared away. And by adopting a curing forming scheme, welding spots or riveting spots can be reduced, so that the structural strength can be improved, and the production labor intensity can be reduced.

Description

Technical Field

[0001] The invention relates to the technical field of railway freight train technical inspection, in particular to a kind of. Background Art

[0002] Lightweighting of railway freight cars refers to maximizing the structural load under the condition of limited load-bearing structure mass and meeting the structural safety and reliability, thereby improving the vehicle's carrying capacity and energy consumption;

[0003] In terms of vehicle lightweighting, the deadweight coefficient of my country's 70t-class trucks is 0.34, and the deadweight coefficient of 80t-class trucks is 0.25. The deadweight coefficient of many special trucks in the United States is only 0.17. These gaps, especially in the lightweight technology of railway trucks, are closely related to the application of advanced lightweight materials in railway trucks.

[0004] The body of a railway freight car is mainly composed of a chassis, end walls and side walls, among which: the chassis is mainly welded together by a center beam, a pillow beam, a cross beam, a longitudinal beam and a floor; the end wall is mainly composed of an end plate, an upper end beam, a cross strap and a corner column; the side wall is mainly composed of an upper side beam, a pillow column, a side column and a side wall plate; the three together enclose a cargo loading space and an overall load-bearing structure; the end wall and the side wall are mainly used to withstand the lateral pressure of the loaded cargo and the lateral force generated by the vehicle during operation, especially the longitudinally arranged side walls need to withstand greater pressure, so the side walls must have sufficient strength and rigidity to ensure the safety of the railway open car operation. Summary of the invention

[0005] The invention provides a composite material side wall of a railway freight car and a manufacturing method thereof, which are used to enhance the strength and rigidity of the side wall and ensure the safety of railway open car operation.

[0006] The present invention provides a composite material side wall of a railway freight car and a manufacturing method thereof, comprising:

[0007] A skin, wherein the skin is composed of an inner skin and an outer skin;

[0008] A first support assembly is arranged between the inner skin and the outer skin, the first support assembly comprises a plurality of groups of cross beam assemblies and a plurality of groups of side vertical beams, the plurality of groups of cross beam assemblies are evenly spaced and laterally distributed, the plurality of groups of side vertical beams are arranged at both ends of the inner part of the skin, and the side vertical beams are arranged vertically;

[0009] A second support assembly is arranged between the inner skin and the outer skin, the second support assembly includes a vertical beam assembly and an oblique connecting beam, the vertical beam assembly is provided with a plurality of groups, the plurality of groups of vertical beam assemblies are vertically spaced and distributed, and the oblique connecting beams are located at both sides of the inner bottom end of the skin;

[0010] A filling component is filled in the interior of the skin, wherein the filling component comprises a third sandwich material.

[0011] Preferably, the inner skin and the outer skin have the same size, and the inner skin includes a layer of epoxy prepreg wear-resistant layer reinforced with glass fiber plain cloth, a layer of epoxy prepreg layer reinforced with carbon fiber plain cloth, eighteen layers of epoxy prepreg unidirectional tape layers reinforced with carbon fiber plain cloth, and a layer of epoxy prepreg layer reinforced with carbon fiber plain cloth.

[0012] Preferably, the outer skin comprises one layer of epoxy prepreg layer reinforced with carbon fiber plain weave cloth, eighteen layers of epoxy prepreg unidirectional tape layers reinforced with carbon fiber plain weave cloth, and one layer of epoxy prepreg layer reinforced with carbon fiber plain weave cloth, and the laying order is one layer of fabric layer, twelve to eighteen layers of unidirectional tape layers, and one layer of fabric layer.

[0013] Preferably, the unidirectional tape layers are laid symmetrically in the longitudinal direction of [45°, -45°, 0°], and the curing temperature of the prepreg is 80-120°C.

[0014] Preferably, the crossbeam assembly and the side vertical beam are both composed of an I-beam and a first sandwich material, the first sandwich material is filled inside the I-beam, and the outer surface of the first sandwich material is coated with a first epoxy resin film, and the first sandwich material is connected to the inner side of the I-beam through the first epoxy resin film.

[0015] Preferably, the cross beam assembly is provided in three groups, and the three groups of cross beam assemblies are respectively arranged at the upper, middle and lower positions inside the skin;

[0016] There are four side vertical beams, and the four side vertical beams are respectively arranged on both sides of the two ends of the third sandwich material.

[0017] Preferably, the vertical beam assembly comprises a surface composite material surface layer, the front end or rear end of the surface composite material surface layer is set as a drilling area, the front end of the drilling area is provided with an insert joint area, the insert joint area is adapted to the cross beam assembly, and the interior of the drilling area is filled with thermosetting phenolic resin;

[0018] The drilling area is provided with a plurality of groups of nail holes which are spaced apart from each other at positions corresponding to the crossbeam assembly, and the vertical beam assembly is connected to the crossbeam assembly via the plurality of groups of nail holes.

[0019] Preferably, the interior of the surface composite material surface layer is filled with a second sandwich material, and a second epoxy resin film is coated between the outer surface of the second sandwich material and the thermosetting phenolic resin and the inner wall of the surface composite material surface layer.

[0020] Preferably, the cross section of the oblique connecting beam is a trapezoidal structure, and the oblique connecting beam is provided with a plurality of groups of nail holes distributed at intervals;

[0021] Reinforced areas are arranged on both sides of the bottom of the skin at positions corresponding to the oblique connecting beams.

[0022] Preferably, the method for manufacturing a composite material side wall of a railway freight car comprises the following steps:

[0023] S1. Mould making: Make side wall mould according to design specifications;

[0024] S2. Raw material laying: Lay the inner skin according to the design requirements. After the inner skin is laid, lay a layer of epoxy film;

[0025] Place the crossbeam assembly, vertical beam assembly, side vertical beam, oblique connecting beam, and third sandwich material at the designed position on the inner skin, and position them well through tooling pallets to ensure that the components fit each other;

[0026] A layer of foam glue is filled between the third sandwich material and the cross beam assembly, the vertical beam assembly, the side vertical beams, and the oblique connecting beams;

[0027] After the cross beam assembly, the vertical beam assembly, the side vertical beam, the oblique connecting beam and the third sandwich material are laid, a layer of epoxy film is laid;

[0028] Lay the outer skin according to design requirements;

[0029] S3, integrated curing: The laid side wall panels are vacuum packaged, the vacuum degree during packaging is ≤-90kPa, and then placed in a curing device for curing and molding according to the curing system requirements;

[0030] S4, demoulding and trimming: demoulding the product after curing, trimming and grinding the product, surface coating as needed, and completing the side wall preparation.

[0031] Preferably, the vertical beam assemblies are provided in 12 groups, and the 12 groups of vertical beam assemblies are evenly arranged vertically.

[0032] Preferably, the oblique connecting beam is a thermosetting phenolic resin molded plate.

[0033] Preferably, the third sandwich material can be PMI foam, which has a compressive strength of 2.8 MPa.

[0034] Preferably, the third sandwich material can be made of aramid honeycomb, which has a compressive strength of 1.5 MPa.

[0035] Preferably, the I-beam is produced by pultrusion process from carbon fiber and epoxy resin.

[0036] Preferably, the cross beam assembly, the vertical beam assembly, the side vertical beams, and the oblique connecting beams have the same thickness.

[0037] Preferably, the first sandwich material is PMI foam.

[0038] Preferably, the second sandwich material is PMI foam.

[0039] Compared with the prior art, the advantages of the present invention are:

[0040] 1. The crossbeam assembly, vertical beam assembly and side vertical beams are all made of composite material structure, which can reduce weight by more than 30% compared with the most advanced aluminum alloy side wall;

[0041] 2. The side wall adopts an integral structure of skin plus the third sandwich material plus a crossbeam assembly, a vertical beam assembly, a side vertical beam, and an oblique connecting beam. The crossbeam assembly, the vertical beam assembly, the side vertical beam, the oblique connecting beam and the third sandwich material are all solidified inside the skin. The side wall has a simple exterior structure without an outer column, so that the truck limit can be fully utilized and it is also convenient to clean up the goods remaining in the truck;

[0042] 3. The curing molding solution can reduce welding points or rivet points, thereby improving structural strength and reducing production labor intensity. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Hereinafter, the present invention will be described in more detail based on embodiments and with reference to the accompanying drawings.

[0044] Figure 1 is a schematic diagram of a side wall structure in an embodiment of the present invention;

[0045] Figure 2 is a schematic cross-sectional view of a side wall structure in an embodiment of the present invention;

[0046] Figure 3 It is a cross-sectional schematic diagram of the cross beam assembly and the side vertical beam structure of the present invention;

[0047] Figure 4 is a vertical cross-sectional schematic diagram of a vertical beam assembly of the present invention;

[0048] Figure 5 is a schematic transverse cross-sectional view of a vertical beam assembly of the present invention;

[0049] Figure 6 It is a schematic cross-sectional view of the oblique connecting beam of the present invention.

[0050] Reference numerals:

[0051] Skin 1, inner skin 11, outer skin 12;

[0052] Crossbeam assembly 2, I-beam 21, first sandwich material 22, first epoxy resin film 23;

[0053] Vertical beam assembly 3, nail hole 31, plug-in joint area 32, drilling area 33, second sandwich material 34, second epoxy resin film 35, surface composite material surface layer 36;

[0054] Side vertical beam 4;

[0055] Oblique connecting beam 5;

[0056] The third sandwich material 6;

[0057] Epoxy structural adhesive film layer 7;

[0058] Strengthening of area 8. DETAILED DESCRIPTION

[0059] In order to more clearly illustrate the overall concept of the present invention, a detailed description is given below in an exemplary manner in conjunction with the accompanying drawings.

[0060] It should be noted that many specific details are set forth in the following description to facilitate a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Therefore, the protection scope of the present invention is not limited to the specific embodiments disclosed below.

[0061] In addition, in the description of the present invention, it should be understood that the terms "center", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "axial", "radial", "circumferential" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0062] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral one; it can be directly connected, or indirectly connected through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. However, if it is indicated as a direct connection, it means that the two connected bodies are not connected through an intermediate structure, but are only connected to form a whole through a connecting structure. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances.

[0063] In the present invention, unless otherwise clearly specified and limited, the first feature "on" or "under" the second feature may be that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in an appropriate manner in any one or more embodiments or examples.

[0064] A composite side wall of a railway freight car, comprising:

[0065] A skin 1, wherein the skin 1 is composed of an inner skin 11 and an outer skin 12;

[0066] The inner skin 11 and the outer skin 12 have the same size, and the inner skin 11 includes one layer of epoxy prepreg wear-resistant layer reinforced by glass fiber plain weave cloth, one layer of epoxy prepreg layer reinforced by carbon fiber plain weave cloth, eighteen layers of epoxy prepreg unidirectional tape layers reinforced by carbon fiber plain weave cloth, and one layer of epoxy prepreg layer reinforced by carbon fiber plain weave cloth;

[0067] The outer skin 12 includes one layer of epoxy prepreg reinforced by carbon fiber plain weave cloth, twelve to eighteen layers of carbon fiber reinforced epoxy prepreg unidirectional tape layers, and one layer of epoxy prepreg reinforced by carbon fiber plain weave cloth;

[0068] The unidirectional tape layers are laid symmetrically in the longitudinal direction of [45°, -45°, 0°], and the curing temperature of the prepreg is 80-120°C;

[0069] A first support assembly is arranged between the inner skin 11 and the outer skin 12, the first support assembly includes a plurality of groups of cross beam assemblies 2 and a plurality of groups of side vertical beams 4, the plurality of groups of cross beam assemblies 2 and the plurality of groups of side vertical beams 4 are both composed of an I-beam 21 and a first sandwich material 22, the plurality of groups of cross beam assemblies 2 are evenly spaced and laterally distributed, the plurality of groups of side vertical beams 4 are arranged at both ends of the inner part of the skin 1, and the plurality of groups of side vertical beams 4 are arranged vertically;

[0070] The cross beam assembly 2 is provided in three groups, and the three groups of cross beam assembly 2 are respectively arranged at the upper, middle and lower positions inside the skin 1;

[0071] There are four side vertical beams 4, and the four side vertical beams 4 are respectively arranged on both ends of the third sandwich material 6;

[0072] The first sandwich material 22 is filled inside the I-beam 21, and the outer surface of the first sandwich material 22 is coated with a first epoxy resin film 23, and the first sandwich material 22 is connected to the inner side of the I-beam 21 through the first epoxy resin film 23;

[0073] A second support assembly is arranged between the inner skin 11 and the outer skin 12, and the second support assembly includes a vertical beam assembly 3 and an oblique connecting beam 5. The vertical beam assembly 3 is provided with a plurality of groups, and the plurality of groups of the vertical beam assembly 3 are vertically spaced and distributed, and the vertical beam assembly 3 is composed of a surface composite material surface layer 36 and a second sandwich material 34, and the oblique connecting beam 5 is located at both sides of the inner bottom end of the skin 1;

[0074] The front end or rear end of the surface composite material surface layer 36 is set as a drilling area 33, and the front end of the drilling area 33 is provided with an insert joint area 32, the insert joint area 32 is adapted to the cross beam assembly 2, and the interior of the surface composite material surface layer 36 corresponding to the position of the drilling area 33 is filled with thermosetting phenolic resin;

[0075] The drilling area 33 is provided with a plurality of groups of nail holes 31 spaced apart at positions corresponding to the cross beam assembly 2, and the vertical beam assembly 3 is connected to the cross beam assembly 2 through the plurality of groups of nail holes 31;

[0076] The interior of the surface composite material surface layer 36 is filled with a second sandwich material 34, and a second epoxy resin film 35 is coated between the outer surface of the second sandwich material 34 and the thermosetting phenolic resin and the inner wall of the surface composite material surface layer 36;

[0077] The cross section of the oblique connecting beam 5 is a trapezoidal structure, and a plurality of groups of nail holes 31 distributed at intervals are provided on the oblique connecting beam 5;

[0078] A filling component, filled in the interior of the skin 1, the filling component comprising a third sandwich material 6;

[0079] An epoxy structural adhesive film layer 7 is coated between the cross beam assembly 2, the vertical beam assembly 3, the side vertical beams 4, the oblique connecting beams 5 and the third sandwich material 6 and the skin 1 and the cross beam assembly 2;

[0080] Reinforced areas 8 are provided on both sides of the bottom of the skin 1 at positions corresponding to the oblique connecting beams 5 .

[0081] A method for manufacturing a composite material side wall of a railway freight car comprises the following steps:

[0082] S1. Mould making: Make side wall mould according to design specifications;

[0083] S2, laying of raw materials: laying the inner skin 11 according to the design requirements, and after the inner skin 11 is laid, laying a layer of epoxy film;

[0084] Place the crossbeam assembly 2, the vertical beam assembly 3, the side vertical beam 4, the oblique connecting beam 5, and the third sandwich material 6 at the designed position on the inner skin 11, and position them well through the tooling card to ensure that the components fit each other;

[0085] A layer of foam glue is filled between the third sandwich material 6 and the cross beam assembly 2, the vertical beam assembly 3, the side vertical beam 4, and the oblique connecting beam 5;

[0086] After the cross beam assembly 2, the vertical beam assembly 3, the side vertical beam 4, the oblique connecting beam 5 and the third sandwich material 6 are laid, a layer of epoxy film is laid;

[0087] Lay the outer skin 12 according to the design requirements;

[0088] S3, integrated curing: The laid side wall panels are vacuum packaged, the vacuum degree during packaging is ≤-90kPa, and then placed in a curing device for curing and molding according to the curing system requirements;

[0089] S4, demoulding and trimming: demoulding the product after curing, trimming and grinding the product, surface coating as needed, and completing the side wall preparation.

[0090] Embodiment 1:

[0091] See also Figure 1 As shown, Figure 1 is a schematic diagram of a side wall structure in an embodiment of the present invention;

[0092] See also Figure 2 As shown, Figure 2 is a schematic cross-sectional view of a side wall structure in an embodiment of the present invention;

[0093] like Figure 1-Figure 2 As shown, a composite side wall of a railway freight car is composed of a skin 1, a crossbeam assembly 2, a vertical beam assembly 3, a side vertical beam 4, an oblique connecting beam 5, and a third sandwich material 6. The skin 1 is composed of an inner skin 11 and an outer skin 12, and the crossbeam assembly 2, the vertical beam assembly 3, the side vertical beam 4, the oblique connecting beam 5, and the third sandwich material 6 are all arranged between the inner skin 11 and the outer skin 12, and the crossbeam assembly 2, the vertical beam assembly 3, the side vertical beam 4, the oblique connecting beam 5, the third sandwich material 6 and the inner skin 11 and the outer skin 12 are all covered with an epoxy structural adhesive film layer 7. Under high temperature conditions, the epoxy structural adhesive film layer 7 is cured, so that the crossbeam assembly 2, the vertical beam assembly 3, the side vertical beam 4, the oblique connecting beam 5, and the third sandwich material 6 can be fixed inside the skin 1;

[0094] The side wall adopts an integral structure of a skin 1 plus a third sandwich material 6 plus a crossbeam assembly 2, a vertical beam assembly 3, a side vertical beam 4, and an oblique connecting beam 5. The crossbeam assembly 2, the vertical beam assembly 3, the side vertical beam 4, the oblique connecting beam 5 and the third sandwich material 6 are all solidified inside the skin 1. The outer structure of the side wall is simple and is a structure without an outer column, so that the truck limit can be fully utilized and it is also convenient to clean up the goods remaining in the truck.

[0095] At the same time, the use of a curing molding solution can reduce welding points or rivet points, thereby improving structural strength and reducing production labor intensity.

[0096] The third sandwich material 6 may be PMI foam;

[0097] The third sandwich material 6 can be made of aramid honeycomb.

[0098] Embodiment 2:

[0099] On the basis of the first embodiment, the inner skin 11 and the outer skin 12 have the same size, and the inner skin 11 includes one layer of epoxy prepreg wear-resistant layer reinforced by glass fiber plain weave cloth, one layer of epoxy prepreg layer reinforced by carbon fiber plain weave cloth, eighteen layers of epoxy prepreg unidirectional tape layers reinforced by carbon fiber plain weave cloth, and one layer of epoxy prepreg layer reinforced by carbon fiber plain weave cloth;

[0100] The outer skin 12 includes one layer of epoxy prepreg reinforced by carbon fiber plain weave cloth, twelve to eighteen layers of carbon fiber reinforced epoxy prepreg unidirectional tape layers, and one layer of epoxy prepreg reinforced by carbon fiber plain weave cloth;

[0101] The unidirectional tape layers are laid symmetrically in the longitudinal direction of [45°, -45°, 0°], and the curing temperature of the prepreg is 80-120°C;

[0102] The outer surface strength of the side wall is enhanced by the coordination of the epoxy prepreg wear-resistant layer, the epoxy prepreg layer, the epoxy prepreg unidirectional tape layer and the epoxy prepreg layer, as well as the fabric layer and the fabric layer.

[0103] Embodiment three:

[0104] See also Figure 3 As shown, Figure 3 It is a cross-sectional schematic diagram of the cross beam assembly and the side vertical beam structure of the present invention;

[0105] like Figure 3As shown, a composite side wall of a railway freight car comprises a first support assembly, which is arranged between the inner skin 11 and the outer skin 12, wherein the first support assembly comprises a plurality of groups of cross beam assemblies 2 and a plurality of groups of side vertical beams 4, wherein the plurality of groups of cross beam assemblies 2 and the plurality of groups of side vertical beams 4 are both composed of I-beams 21 and a first sandwich material 22, wherein the plurality of groups of cross beam assemblies 2 are evenly spaced and laterally distributed, the plurality of groups of side vertical beams 4 are arranged at both ends of the inner part of the skin 1, and the plurality of groups of side vertical beams 4 are arranged vertically;

[0106] The cross beam assembly 2 is provided in three groups, and the three groups of cross beam assembly 2 are respectively arranged at the upper, middle and lower positions inside the skin 1;

[0107] There are four side vertical beams 4, and the four side vertical beams 4 are respectively arranged on both ends of the third sandwich material 6;

[0108] The first sandwich material 22 is filled inside the I-beam 21, and the outer surface of the first sandwich material 22 is coated with a first epoxy resin film 23, and the first sandwich material 22 is connected to the inner side of the I-beam 21 through the first epoxy resin film 23;

[0109] The cross beam assembly 2 and the side vertical beam 4 form a composite material through the cooperation of the I-beam 21 and the first sandwich material 22, which reduces the overall weight of the side wall. At the same time, the arrangement and cooperation of multiple groups of cross beam assemblies 2 and side vertical beams 4 improve the strength and rigidity of the side wall.

[0110] The I-beam 21 is made of carbon fiber and epoxy resin through a pultrusion process.

[0111] Embodiment 4:

[0112] See also Figure 4 As shown, Figure 4 is a vertical cross-sectional schematic diagram of a vertical beam assembly of the present invention;

[0113] See also Figure 5 As shown, Figure 5 Schematic diagram of the transverse section of the vertical beam assembly of the present invention

[0114] like Figure 4-Figure 5 As shown, a composite side wall of a railway freight car includes a second support assembly, which is arranged between the inner skin 11 and the outer skin 12, and the second support assembly includes a vertical beam assembly 3 and an oblique connecting beam 5. The vertical beam assembly 3 is provided with multiple groups, and the multiple groups of the vertical beam assemblies 3 are vertically spaced and distributed, and the vertical beam assembly 3 is composed of a surface composite material surface layer 36 and a second sandwich material 34, and the oblique connecting beam 5 is located on both sides of the inner bottom end of the skin 1;

[0115] The front end or rear end of the surface composite material surface layer 36 is set as a drilling area 33, and the front end of the drilling area 33 is provided with an insert joint area 32, the insert joint area 32 is adapted to the cross beam assembly 2, and the interior of the surface composite material surface layer 36 corresponding to the position of the drilling area 33 is filled with thermosetting phenolic resin;

[0116] The drilling area 33 is provided with a plurality of groups of nail holes 31 spaced apart at positions corresponding to the cross beam assembly 2, and the vertical beam assembly 3 is connected to the cross beam assembly 2 through the plurality of groups of nail holes 31;

[0117] The interior of the surface composite material surface layer 36 is filled with a second sandwich material 34, and a second epoxy resin film 35 is coated between the outer surface of the second sandwich material 34 and the thermosetting phenolic resin and the inner wall of the surface composite material surface layer 36;

[0118] The strength of the vertical beam assembly 3 itself is achieved by means of a surface composite material surface layer 36 and a second sandwich material 34 and a thermosetting phenolic resin filled inside the surface composite material surface layer 36. At the same time, an insert joint area 32 is provided at the end of the vertical beam assembly 3, and the connection between the vertical beam assembly 3 and the cross beam assembly 2 is achieved through the insert joint area 32. At the same time, nail holes 31 are opened on the insert joint area 32, and the fixation of the cross beam assembly 2 and the vertical beam assembly 3 is achieved through the nail holes 31.

[0119] Embodiment five:

[0120] See also Figure 6 As shown, Figure 6 is a schematic cross-sectional view of an oblique connecting beam of the present invention;

[0121] like Figure 6 As shown, the oblique connecting beam is a thermosetting phenolic resin molded plate, the cross section of the oblique connecting beam 5 is a trapezoidal structure, and the oblique connecting beam 5 is provided with a plurality of groups of nail holes 31 distributed at intervals;

[0122] The oblique connecting beam 5 is fixed inside the skin 1 through the nail holes 31 opened on the oblique connecting beam 5;

[0123] The edge of the oblique connecting beam 5 is aligned with the edge of the third sandwich material 6 inside the skin 1 .

[0124] Embodiment six:

[0125] See also Figure 2 As shown, Figure 2 is a schematic cross-sectional view of a side wall structure in an embodiment of the present invention;

[0126] See also Figure 3 As shown, Figure 3 It is a cross-sectional schematic diagram of the cross beam assembly and the side vertical beam structure of the present invention;

[0127] See also Figure 4 As shown, Figure 4 is a vertical cross-sectional schematic diagram of a vertical beam assembly of the present invention;

[0128] See also Figure 5 As shown, Figure 5 is a schematic transverse cross-sectional view of a vertical beam assembly of the present invention;

[0129] like Figure 2-Figure 5 As shown, the cross beam assembly 2, the vertical beam assembly 3, the side vertical beam 4, and the diagonal connecting beam 5 are flush in the thickness direction and are fixed inside the skin 1 by tooling to ensure the fit of the third sandwich material 6, and a layer of foam glue can be coated between the third sandwich material 6 and the cross beam assembly 2, the vertical beam assembly 3, the side vertical beam 4, and the diagonal connecting beam 5.

[0130] Those skilled in the art should understand that the discussion of any of the above embodiments is merely illustrative and is not intended to imply that the scope of the present invention (including the claims) is limited to these examples. Under the concept of the present invention, the technical features in the above embodiments or different embodiments may be combined, the steps may be implemented in any order, and there are many other variations of the different aspects of the present invention as described above, which are not provided in detail for the sake of simplicity.

[0131] The present invention is intended to cover all such substitutions, modifications and variations that fall within the broad scope of the appended claims. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A composite side wall of a railway freight car, characterized in that: include: The skin is composed of an inner skin and an outer skin, the inner skin includes an epoxy prepreg wear-resistant layer, an epoxy prepreg layer, an epoxy prepreg unidirectional tape layer and an epoxy prepreg layer, and the outer skin includes a fabric layer, a unidirectional tape layer and a fabric layer; A first support assembly is arranged between the inner skin and the outer skin, the first support assembly includes a plurality of groups of cross beam assemblies and a plurality of groups of side vertical beams, the plurality of groups of cross beam assemblies and the plurality of groups of side vertical beams are both composed of I-beams and a first sandwich material, the plurality of groups of cross beam assemblies are evenly spaced and laterally distributed, the plurality of groups of side vertical beams are arranged at both ends of the inner part of the skin, and the plurality of groups of side vertical beams are arranged vertically; A second support assembly is arranged between the inner skin and the outer skin, the second support assembly includes a vertical beam assembly and an oblique connecting beam, the vertical beam assembly is provided with a plurality of groups, the plurality of groups of the vertical beam assemblies are vertically spaced and the vertical beam assembly is composed of a surface composite material surface layer and a second sandwich material, and the oblique connecting beam is located at both sides of the inner bottom end of the skin; A filling component, filled in the interior of the skin, the filling component comprising a third sandwich material; The epoxy structural adhesive film layer is coated on the cross beam assembly, the vertical beam assembly, the side vertical beams, the oblique connecting beams and the third sandwich material and between the skin and the cross beam assembly.

2. The composite side wall of a railway freight car according to claim 1, characterized in that: The inner skin and the outer skin have the same size, and the inner skin includes one layer of epoxy prepreg wear-resistant layer reinforced by glass fiber plain weave cloth, one layer of epoxy prepreg layer reinforced by carbon fiber plain weave cloth, eighteen layers of epoxy prepreg unidirectional tape layers reinforced by carbon fiber plain weave cloth, and one layer of epoxy prepreg layer reinforced by carbon fiber plain weave cloth.

3. The composite side wall of a railway freight car according to claim 2, characterized in that: The outer skin comprises one layer of epoxy prepreg reinforced by carbon fiber plain weave cloth, twelve to eighteen layers of carbon fiber reinforced epoxy prepreg unidirectional tape layers, and one layer of epoxy prepreg reinforced by carbon fiber plain weave cloth.

4. The composite side wall of a railway freight car according to claim 3, characterized in that: The unidirectional tape layers are laid symmetrically in the longitudinal direction of [45°, -45°, 0°], and the curing temperature of the prepreg is 80-120°C.

5. The composite side wall of a railway freight car according to claim 2, characterized in that: The first sandwich material is filled inside the I-beam, and the outer surface of the first sandwich material is coated with a first epoxy resin film, and the first sandwich material is connected to the inner side of the I-beam through the first epoxy resin film.

6. The composite side wall of a railway freight car according to claim 5, characterized in that: The cross beam assembly is provided in three groups, and the three groups of cross beam assemblies are respectively arranged at the upper, middle and lower positions inside the skin; There are four side vertical beams, and the four side vertical beams are respectively arranged on both sides of the two ends of the third sandwich material.

7. The composite side wall of a railway freight car according to claim 5, characterized in that: The front end or rear end of the surface composite material surface layer is set as a drilling area, the front end of the drilling area is provided with an insert joint area, the insert joint area is adapted to the crossbeam assembly, and the interior of the surface composite material surface layer is filled with thermosetting phenolic resin at a position corresponding to the drilling area; The drilling area is provided with a plurality of groups of nail holes which are spaced apart from each other at positions corresponding to the crossbeam assembly, and the vertical beam assembly is connected to the crossbeam assembly via the plurality of groups of nail holes.

8. The composite side wall of a railway freight car according to claim 6, characterized in that: The interior of the surface composite material surface layer is filled with a second sandwich material, and a second epoxy resin film is coated between the outer surface of the second sandwich material and the thermosetting phenolic resin and the inner wall of the surface composite material surface layer.

9. The composite side wall of a railway freight car according to claim 6, characterized in that: The cross section of the oblique connecting beam is a trapezoidal structure, and the oblique connecting beam is provided with a plurality of groups of nail holes distributed at intervals; Reinforced areas are arranged on both sides of the bottom of the skin at positions corresponding to the oblique connecting beams.

10. A method for manufacturing a composite side wall of a railway freight car, comprising the following steps: S1. Mould making: Make side wall mould according to design specifications; S2. Raw material laying: Lay the inner skin according to the design requirements. After the inner skin is laid, lay a layer of epoxy film; Place the crossbeam assembly, vertical beam assembly, side vertical beam, oblique connecting beam, and third sandwich material at the designed position on the inner skin, and position them well through tooling pallets to ensure that the components fit each other; A layer of foam glue is filled between the third sandwich material and the cross beam assembly, the vertical beam assembly, the side vertical beams, and the oblique connecting beams; After the cross beam assembly, the vertical beam assembly, the side vertical beam, the oblique connecting beam and the third sandwich material are laid, a layer of epoxy film is laid; Lay the outer skin according to design requirements; S3, integrated curing: The laid side wall panels are vacuum packaged, the vacuum degree during packaging is ≤-90kPa, and then placed in a curing device for curing and molding according to the curing system requirements; S4, demoulding and trimming: demoulding the product after curing, trimming and grinding the product, surface coating as needed, and completing the side wall preparation.

Images